Popper Mold-Tech received a project to develop a mold for medical lighting equipment. The client required high heat resistance and lightweight material for the light housing. As a leading injection mould company, we accepted the challenge and proceeded with our reliable mold maker process.
Understanding Client Requirements
The lighting equipment needed to be lightweight, strong, and able to withstand high temperatures from the bulbs. Our mold maker team began by analyzing the design. We noted the thin walls of the light housing and anticipated problems with material flow during injection molding. We worked closely with the client to refine the design.
Material Selection and Testing
For this project, the material had to handle heat without warping or cracking. Our mold maker experts recommended polycarbonate. This material is known for its high heat resistance and strength, perfect for medical lighting equipment.
We proceeded with the first mold prototype, but during injection molding, we encountered flow issues. The plastic wasn’t reaching all parts of the mold. To fix this, our injection mould company team adjusted the gate placement and increased the injection pressure. This ensured the material flowed evenly throughout the mold.
Cooling System Challenges
After fixing the flow issue, another problem arose. The cooling system wasn’t working efficiently. This caused surface defects on the light housing, which made it unacceptable for the client.
Our mold maker team redesigned the cooling channels. We ensured even cooling to avoid surface defects. Once this issue was resolved, the injection molding process produced clean, defect-free parts.
Final Adjustments and Production
After solving the cooling issue, we provided the client with samples. They approved the design and performance of the medical lighting equipment. Our injection mould company then proceeded with full production.
Medical lighting equipment requires precision and heat resistance. Our mold maker expertise ensured the final product met the client’s high standards. Through problem-solving and injection molding experience, Popper Mold-Tech delivered a top-quality mold.